Polycrystalline ultra-hard compact constructions

ABSTRACT

Polycrystalline ultra-hard compact constructions comprise a polycrystalline ultra-hard compact having a polycrystalline ultra-hard body attached to a substrate. A support member is attached to the compact by a braze material. The support member can have a one-piece construction including one or more support sections. The support member has a first section extending axially along a wall surface of the compact, and extending circumferentially along a portion of the compact. The support member can include a second section extending radially along a backside surface of the compact, and/or a third section extending radially along a front side surface of the compact. In one embodiment, the support member includes a second and/or third section and the compact disposed therein is in an axially compressed state. The support member is interposed between the compact and an end-use device to improve the compact attachment strength with respect to the end-use device.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 11/971,893, filed Jan. 9, 2008, which is incorporated byreference in its entirety.

FIELD OF THE INVENTION

This invention generally relates to polycrystalline ultra-hard compactsand, more particularly, to polycrystalline diamond compact constructionsthat have been specially engineered to include a support member toprovide improved bond strength when attached to a desired cutting and/orwear device when compared to conventional polycrystalline compacts.

BACKGROUND OF THE INVENTION

Polycrystalline ultra-hard constructions, such as polycrystallinediamond (PCD) materials and PCD elements formed therefrom, are wellknown in the art. Conventional PCD is formed by subjecting diamondgrains to processing conditions of extremely high pressure and hightemperature in the presence of a suitable solvent catalyst material,wherein the solvent catalyst material promotes desired intercrystallinediamond-to-diamond bonding between the grains, thereby forming a PCDstructure.

The solvent catalyst material can be combined with the diamond grainsprior to processing or the solvent catalyst material can be providedfrom an outside source, e.g., from an adjacent substrate body or thelike that contains the solvent catalyst material, by infiltration duringprocessing. The resulting PCD structure produces enhanced properties ofwear resistance and hardness, making PCD materials extremely useful inaggressive wear and cutting applications where high levels of wearresistance and hardness are desired.

Solvent catalyst materials typically used for forming conventional PCDinclude metals selected from Group VIII of the Periodic table, withcobalt (Co) being the most common. Conventional PCD can comprise from 85to 95% by volume diamond and a remaining amount of the solvent catalystmaterial. The solvent catalyst material is disposed within interstitialregions of the PCD microstructure that exist between the bonded togetherdiamond grains or crystals.

PCD as used in certain industrial wear and/or cutting applications, suchas cutting elements in subterranean drill bits, are provided in the formof a compact comprising the PCD material attached to a substrate. ThePCD material is positioned on the substrate at a location to engage thesurface to be cut or worn, and the substrate is provided for the purposeof facilitating attachment of the PCD compact to the end use wear and/orcutting device. Conventional PCD cutters comprise a PCD body that isjoined with a metallic or cermet substrate, e.g., such as one formedfrom cemented tungsten carbide. Such conventional PCD compacts areformed by placing a desired substrate next to the diamond grain volumeand subjecting the combination to high pressure and high temperature(HPHT) processing.

When used as a cutting element in a drill bit, the PCD compact isattached to a portion of the drill bit by welding or brazing. Morespecifically, the PCD compact is attached to the drill bit by welding orbrazing the substrate portion of the PCD compact to a desired portion ofthe drill bit. Conventional PCD compacts configured for use as suchcutting elements have a generally cylindrical shape. Accordingly, whenattached for use with a drill bit, the cylindrical PCD compact substrateis brazed or welded to the desired body portion of the drill bit.

A problem known to exist with such conventional PCD compacts configuredas cutting elements for use with subterranean drill bits is that the PCDcompacts fracture during the process of drilling, causing the PCDcompact to break away from and fall off of the drill bit body. Suchfracturing is known to occur at the point of attachment between the PCDcompact substrate and the drill bit.

In addition to PCD, another form of polycrystalline diamondconventionally used for its desired properties of wear and/or abrasionresistance is one that is substantially free of the catalyst materialused to form the PCD. This type of polycrystalline diamond is known asthermally stable polycrystalline diamond (TSP) because it is also knownto have improved thermal properties when compared to conventional PCD.While such TSP materials do provide certain performance advantages, thedesired lack of catalyst material makes it difficult to form a compactconstruction having a substrate attached to the TSP material. Thepresence of a substrate is desired to facilitate attachment of theconstruction to an end-use wear and/or cutting device. The substratesfor such TSP construction are conventionally attached to the TSPmaterial by welding or brazing, which attachment has shown to bevulnerable to failure in operation.

It is, therefore, desired that polycrystalline ultra-hard constructionsbe configured in a manner that is specially engineered and designed toprovide an enhanced degree of contact between a PCD compact and the wearand/or cutting device to maximize the attachment therebetween, andthereby minimize and/or eliminate the possibility of the PCD compactfracturing or otherwise becoming detached from the wear and/or cuttingdevice during use. It is desired that the PCD compact be configured in amanner that contributes to the overall strength of the PCD compactitself. It is further desired that the polycrystalline ultra-hardconstructions be configured in a manner engineered to place thepolycrystalline ultra-hard material and substrate attached thereto, in astate of compression to thereby improve the attachment strength betweenthe polycrystalline ultra-hard body and a substrate included in theconstruction.

SUMMARY OF THE INVENTION

Polycrystalline ultra-hard compact constructions of this inventioncomprise a polycrystalline ultra-hard compact that includes apolycrystalline ultra-hard body that is attached to a substrate. In anexample embodiment, the body can comprise polycrystalline diamond thatmay or may not be substantially free of a catalyst material. A speciallyengineered support member is attached to the compact by a brazematerial, and is configured to provide an improved degree of attachmentbetween the compact and a desired end-use wear and/or cutting device.

The support member can be of a one-piece or unitary constructioncomprising one or more sections. In an example embodiment, the supportmember includes a first section that extends axially along a wallsurface of the compact and that is configured to accommodate placementof the compact therealong. The first section extends circumferentiallyaround a portion of the compact wall surface, the extent of suchcircumferential wrap can vary from less than about 50 percent up to 100percent depending on the support member configuration.

The support member can include a second section that extends radiallyalong a backside surface of the compact, and can further include a thirdsection that extends radially along a front side surface of the compact.The second the third sections can extend radially along from about 30 to100 percent of the respective compact backside and front side surfaces.In an example embodiment, the support member includes all three sectionsand the three sections are integral with the support member.Alternatively, the support member may only include one of these sectionsand/or may include two or more of these sections, wherein one or both ofthese sections may not be integral with the support member.

The support member may be configured to place the compact in a state ofaxial compression, which can be achieved when the support memberincludes a second or third section that extends along a respectivecompact backside or front side surface. In an example embodiment, suchaxial compression is achieved during a cooling phase of brazing thecompact to the support member when the support member is formed from amaterial having a thermal expansion characteristic, e.g., a coefficientof thermal expansion, that is greater than that of the compact.

The support member can be attached to the compact by using differentbraze materials, e.g., active and nonactive braze alloys, depending onthe particular compact and/or support member construction and theend-use application. In the case where the support member is provided asa multi-piece component, the different support portions can be formedfrom different materials. The use of different braze materials and/ordifferent support member portions can be tailored to reduce thermalstress during the process of attaching the compact and support member toachieve an improved attachment strength therebetween.

Polycrystalline ultra-hard compacts constructions of this inventionconfigured in this manner are specially engineered to provide anenhanced degree of contact between a polycrystalline ultra-hard compactand a desired wear and/or cutting device to maximize the attachmentstrength therebetween. Further, such constructions of this invention canplace the compact in a state of axial compression that can improve theattachment strength between the polycrystalline ultra-hard body andsubstrate of the compact. Both features of such constructions operate toextend the surface life of polycrystalline ultra-hard compacts as usedin desired wear and/or cutting operations, when compared to conventionalpolycrystalline ultra-hard compacts that do not make use of the supportmember of such constructions.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will beappreciated as the same becomes better understood by reference to thefollowing detailed description when considered in connection with theaccompanying drawings wherein:

FIGS. 1A, 1B and 1C are cross-sectional side views of example embodimentpolycrystalline ultra-hard compact construction of this inventioncomprising differently configured one-piece support members attached toa polycrystalline ultra-hard compact;

FIG. 1D is a front view of the example embodiment polycrystallineultra-hard compact construction of FIG. 1C;

FIGS. 2A and 2B are cross-sectional side views of example embodimentpolycrystalline ultra-hard compact constructions of this inventioncomprising different multi-piece support members attached to apolycrystalline ultra-hard compact;

FIGS. 3A and 3B are respective cross-sectional side and front views ofan example embodiment polycrystalline ultra-hard compact construction ofthis invention comprising a polycrystalline ultra-hard compact attachedto a support member, as attached to an end use device;

FIGS. 4A and 4B are respective cross-sectional side and top front viewsof another example embodiment polycrystalline ultra-hard compactconstruction of this invention, comprising a polycrystalline ultra-hardcompact attached to a support member, as attached to an end use device;

FIG. 5 is a perspective side view of a drag bit comprising a number ofpolycrystalline ultra-hard compact constructions of the inventionprovided in the form of shear cutters;

FIG. 6 is a perspective side view of a rotary cone drill bit comprisinga number of polycrystalline ultra-hard compact constructions of thisinvention provided in the form of inserts; and

FIG. 7 is a perspective side view of a percussion or hammer bitcomprising a number of polycrystalline ultra-hard compact constructionsof this invention provided in the form of inserts.

DETAILED DESCRIPTION

Polycrystalline ultra-hard compact construction of this inventioncomprise a polycrystalline ultra-hard material body that is joined to asubstrate, wherein the joined together body and substrate forms acompact that is further joined to a support member. The support memberis specifically engineered to provide an enhanced degree of support tothe compact, and an enhanced degree of attachment between the compactand a surface of a wear and/or cutting device. The compact can beattached to the support member using one or more different types ofbraze materials to further enhance the strength of the construction,and/or the support member comprise two or more elements or sections madefrom the same or different types of materials to also enhance strengthof the construction by controlling or minimizing the residual thermalstress within the construction after brazing.

Thus, polycrystalline ultra-hard compact construction constructed inaccordance with principles of this invention comprising such supportmembers provide a structure that can be readily attached to a tooling,cutting and/or wear device, e.g., to a bit used for drillingsubterranean formations when the construction is provided in the form ofa cutting element, by conventional means such as by brazing and thelike.

In an example embodiment, polycrystalline ultra-hard materials used toform the polycrystalline ultra-hard body comprises a materialmicrostructure of bonded-together diamond grains or crystals. In certainembodiments, a portion or the entire polycrystalline ultra-hard materialsubstantially free of a catalyst material used to form the body, or thepolycrystalline ultra-hard material may wholly retain the catalystmaterial.

Polycrystalline ultra-hard compact constructions of this invention arespecially designed to provide properties of improved bond strength andreduced residual thermal stress when compared to conventionalpolycrystalline ultra-hard compacts that do not include the supportmember, thereby providing improved service life.

As used herein, the term “PCD” is understood to refer to polycrystallinediamond that has been formed, at high pressure-high temperature (HPHT)conditions, through the use of a catalyst material, such as the metalsolvent catalysts included in Group VIII of the Periodic table. PCDcomprises a polycrystalline phase of bonded-together diamond crystalsand catalyst material that is disposed in interstitial regions betweenthe diamond crystals.

Materials useful for forming a polycrystalline ultra-hard body can beselected from materials including diamond, cubic boron nitride (cBN),and mixtures thereof. When the polycrystalline ultra-hard body comprisesbonded-together diamond crystals, and the body has not otherwise beentreated to remove the solvent catalyst material used to facilitatediamond bonding to form the same, such solvent catalyst material will bedisposed in interstitial regions within the intercrystalline diamondmicrostructure and/or adhered to the surfaces of the diamond crystals.

In an example embodiment, the polycrystalline ultra-hard body comprisesintercrystalline bonded diamond that is formed by bonding togetheradjacent diamond grains or crystals at HPHT conditions, thereby formingpolycrystalline diamond (PCD). The bonding together of the diamondgrains at HPHT conditions is facilitated by the use of an appropriatecatalyst material. In an example embodiment, the catalyst material is ametal solvent catalyst.

Diamond grains useful for forming PCD materials used withpolycrystalline ultra-hard compact constructions of this inventioninclude synthetic diamond powders having an average diameter grain sizein the range of from submicrometer in size to 100 micrometers, and morepreferably in the range of from about 1 to 80 micrometers. The diamondpowder can contain grains having a mono or multi-modal sizedistribution. In an example embodiment, the diamond powder has anaverage particle grain size of approximately 20 micrometers. In theevent that diamond powders are used having differently sized grains, thediamond grains are mixed together by conventional process, such as byball or attritor milling for as much time as necessary to ensure gooduniform distribution.

The diamond grain powder is preferably cleaned, to enhance thesinterability of the powder by treatment at high temperature, in avacuum or reducing atmosphere. The diamond powder mixture is loaded intoa desired container for placement within a suitable HPHT consolidationand sintering device.

The diamond powder may be combined with a desired catalyst material,e.g., a solvent metal catalyst, in the form of a powder to facilitatediamond bonding during the HPHT process and/or the catalyst material canbe provided by infiltration from a substrate positioned adjacent thediamond powder. Suitable catalyst materials include metal solventcatalysts such as those selected from Group VIII elements of thePeriodic table. A particularly preferred metal solvent catalyst iscobalt (Co).

Suitable substrates useful for both forming the compact and infiltratingthe catalyst material can include those used to form conventional PCDmaterials, including carbides, nitrides, carbonitrides, ceramicmaterials, metallic materials, cermet materials, and mixtures thereof. Afeature of such substrate is that it includes a metal solvent catalystthat is capable of melting and infiltrating into the adjacent volume ofdiamond powder to facilitate the formation of diamond-to-diamondintercrystalline bonding during the HPHT process. As noted above,suitable metal solvent catalyst materials include those selected fromGroup VIII elements of the Periodic table. A particularly preferredmetal solvent catalyst is cobalt (Co), and a preferred substratematerial is cemented tungsten carbide (WC-Co).

Alternatively, the diamond powder mixture can be provided in the form ofa green-state part or mixture comprising diamond powder that iscontained by a binding agent, e.g., in the form of diamond tape or otherformable/confirmable diamond mixture product to facilitate themanufacturing process. In the event that the diamond powder is providedin the form of such a green-state part it is desirable that a preheatingstep take place before HPHT consolidation and sintering to drive off thebinder material. In an example embodiment, the PCD material resultingfrom the above-described HPHT process may have a diamond volume contentin the range of from about 85 to 95 percent.

The diamond powder mixture or green-state part is loaded into a desiredcontainer for placement within a suitable HPHT consolidation andsintering device. The HPHT device is activated to subject the containerto a desired HPHT condition to effect consolidation and sintering of thediamond powder. In an example embodiment, the device is controlled sothat the container is subjected to a HPHT process having a pressure ofapproximately 5,500 MPa and a temperature of from about 1,350° C. to1,500° C. for a predetermined period of time. At this pressure andtemperature, the solvent metal catalyst melts and infiltrates into thediamond powder mixture, thereby sintering the diamond grains to formconventional PCD.

While a particular pressure and temperature range for this HPHT processhas been provided, it is to be understood that such HPHT processingconditions can and will vary depending on such factors as the typeand/or amount of metal solvent catalyst used, as well as the type and/oramount of diamond powder used to form the PCD region. After the HPHTprocess is completed, the container is removed from the HPHT device, andthe so-formed PCD compact is removed from the container.

In an example embodiment, the polycrystalline ultra-hard body comprisesa generally homogonous construction comprising a polycrystallinematerial phase and a binder phase. In one such example embodiment, thepolycrystalline phase is formed from intercrystalline bonded diamond andthe binder phase is formed from the catalyst material used to form thesame, wherein the catalyst material is disposed within interstitialregions of the microstructure. Alternatively, the polycrystallineultra-hard body can be constructed comprising two or more regions,wherein one of the regions includes the binder or catalyst material andanother region is substantially free of the binder material. In suchalternative embodiment, the target region that is substantially free ofthe catalyst material can be provided by treating the targeted region sothat the catalyst material is removed therefrom.

Further still, the polycrystalline ultra-hard body can be constructed asdescribed above, to form PCD, and then the so-formed PCD can be treatedto remove substantially all of the catalyst material from the entirebody, thereby resulting in the formation of thermally stablepolycrystalline diamond (TSP).

As used herein, the term “substantially free” when used in referring toamount of binder or catalyst material in the polycrystalline ultra-hardbody is understood to mean that the catalyst material can actually beremoved from a desired region thereof or the entire body, or that thecatalyst material remains in the region or the entire body but has beenreacted or otherwise treated so that it no longer functions in acatalytic function with respect to the surrounding polycrystallinephase. In an example embodiment, the region or entire body that issubstantially free of the binder or catalyst material has had thecatalyst material removed therefrom by suitable process such as bychemical treatment such as by acid leaching or aqua regia bath,electrochemically such as by electrolytic process, by liquid metalsolubility, or by liquid metal infiltration that sweeps the existingcatalyst material away and replaces it with another noncatalyst materialduring a liquid phase sintering process, or by combinations thereof. Inan example embodiment, the catalyst material is removed from thetargeted region of or the entire polycrystalline ultra-hard body by anacid leaching technique, such as that disclosed for example in U.S. Pat.No. 4,224,380.

In an example embodiment, the polycrystalline ultra-hard body cancomprise a first region that is substantially free of the binder orcatalyst material, and a second region that includes the binder orcatalyst material. In an example embodiment, it is desired that thefirst region be positioned along a surface of the body that may or maynot be a cutting and/or working surface to take advantage of improvedthermal stability provided by removal of the catalyst material. In suchembodiment, the first region extends from a cutting and/or workingsurface a desired depth into the body to the second region. The cuttingand/or working surface is understood to include any and all portions ofthe body outer surface, such as the top and/or side surfaces of the bodywhich may or may not actually come into wear or cutting contact duringuse. Accordingly, it is to be understood that the location of thepolycrystalline body region substantially free of the binder or catalystmaterial can be positioned differently depending on the particular enduse wear and/or cutting application.

Generally speaking, polycrystalline ultra-hard compact constructions ofthis invention comprise a polycrystalline ultra-hard material body thatis attached to a substrate, and that is further attached to the supportmember or to two or more sections of the support member by the use ofone or more braze materials. The configuration of the support member,the material used to form the support member or its sections, and thetypes of braze materials that are used to attach the compact to thesupport member and/or attach one support member to another supportmember are specifically engineered to provide a polycrystallineultra-hard compact construction having improved mechanical bond strengthand reduced residual thermal stress when compared to conventional PCDcompacts lacking use of such support member.

FIGS. 1A and 1B illustrate an example embodiment polycrystallineultra-hard compact construction 10 of this invention generallycomprising a polycrystalline ultra-hard compact 12 that is attached to asupport member 14. In an example embodiment, the polycrystallineultra-hard compact 12 comprises a polycrystalline ultra-hard body 16that is attached to a substrate 18. The body can be formed frompolycrystalline ultra-hard materials described above, and in an exampleembodiment is formed from polycrystalline diamond materials such as PCDand TSP. The substrate can be formed from the same type of substratematerials described above, and in an example embodiment is formed fromcemented tungsten carbide (WC-Co). In an example embodiment, where theconstruction is designed for use in a cutting device such as in a bitfor drilling subterranean formations, the compact 12 is provided in theform of a cutting element, e.g., a PCD cutter.

Referring to FIG. 1A, the support member 14 is a one-piece constructionconfigured having an inside wall portion 20 that includes a firstsection 22 that extends axially along an outside wall surface 26 of thecompact 12 so that it covers an outer side surface of both the body 16and the substrate 18. The support first section 22 is integral with thesupport member 14. In an example embodiment, the support first section22 has an axial length that is approximately the same as the compact 12.The first section 22 is configured having a radius of curvature thatcomplements the outside wall surface of the compact, and has a wallstructure 28 that is disposed at least partially around acircumferential portion of the compact outside wall surface 26.

In an example embodiment, it is desired that the support member 14 firstsection 22 be configured so that it extends circumferentially aroundfrom about 10 to 50 percent of the compact outside wall surface,preferably from about 20 to 50 percent, and more preferably from about40 to 50 percent. If the support member 14 first section 22 extendsradially along less than about 10 percent of the compact outside wallsurface, it may not provide a desired amount of contacting surface areawith the compact to provide a desired improved degree of bond orattachment strength between the compact and the support member for usein certain wear and/or cutting applications. The extent that the supportmember extends around the compact will depend on the degree of enhancedsupport that is desired along with the extent that the compact needs tobe exposed for purpose of performing a cutting and/or wear operation.

The support member first section 22 is sized axially so that it extendsalong all or a portion of the compact 12. For example, the support firstsection 22 can be sized so that it extends axially along the entireoutside wall surface 26 of the compact, i.e., covering both the body 16and the substrate 18. In another example, the support first section 22can be sized to that it extends axially along a partial portion of thecompact outside wall surface 26, e.g., so that it covers all or aportion of the substrate 18 and may not extend to cover the body 16. Inan example embodiment, the support member first section 22 is sizedaxially to extend along the compact body and substrate.

The support member 14 includes a second or back section 24 that extendsfrom an axial end of the first section inside wall portion 20, and thatprojects radially inwardly a distance therefrom. The second section 24is integral with the support member. The support member second section24 is configured to extend along at least a partial portion of abackside surface 30 of the compact 12. In the example embodimentillustrated in FIG. 1A, the support member 14 and its first and secondsections are configured as a one-piece/unitary construction, i.e., it isformed from a single piece of suitable material. Alternatively, ifdesired, the first and second sections of the support member can beformed from separate parts that are connected together by suitablemeans, e.g., by brazing or the like.

The distance that the support member second section 24 extends radiallycan and will vary depending on a number of factors such as the type ofmaterials used to form the compact, the specific geometry of thecompact, and/or the particular end-use application. In an exampleembodiment, the support second section 24 extends a distance that issufficient to provide a desired degree of axial support to the compact,providing a desired improvement in the mechanical strength of theoverall construction. In an example embodiment, the support membersecond section 24 will extend radially to cover at least about 10percent of the compact backside surface 30, and can extend to cover theentire or 100 percent of the backside surface if such degree of axialsupport is called for by the end-use application. In example embodiment,the second member extends radially to cover from about 20 to 100 percentof the compact backside surface 30, and more preferably covers in therange of from about 40 to 50 percent of the compact backside surface.

Configured in this manner, the support member first section 22 operatesto provide side or lateral support to the outer side portion or sidewall surface 26 of the compact 12, and the support second section 24operates to provide axial support to the backside portion 30 of thecompact 12, thereby together operating to increase the overallattachment strength of the compact within the construction and in turnincrease the attachment strength of the compact to the desired cuttingand/or wear device.

The first and second sections of the support member 14 are attached torespective adjacent outside surface portions of the compact 12 bybrazing technique through the use of a suitable braze material 32. Thetype of braze material that is used to attach the compact to the supportmember can and will vary depending on such factors as the types ofmaterials used to form the compact, e.g., the body and the substratematerial, and/or the type of material used to form the support member.

Braze materials useful for forming polycrystalline ultra-hard compactconstructions of this invention include those selected from the groupcomprising Ag, Au, Cu, Ni, Pd, B, Cr, Si Ti, Mo, V, Fe, Al, Mn, Co, andmixtures and alloys thereof. Alloys comprising two or more of theabove-identified materials are especially desired and useful for thispurpose. Brazing materials useful for attaching the compact to thesupport member include those characterized as being “active” and“nonactive.” “Active” braze materials are those that react with thepolycrystalline ultra-hard material, and for this reason are preferablyused for attaching the body portion of the compact to the supportmember, while “nonactive” braze materials are those that do notnecessarily react with the polycrystalline ultra-hard material, and forthis reason may be useful for attaching the substrate portion of thecompact to the support member. While the above preferred uses of“active” and “nonactive” braze materials have been described, it is tobe understood that this is a preferred use and that the braze materialsdescribed herein can be used to attach the polycrystalline ultra-hardcompact to the support member.

Example “active” braze materials useful for forming polycrystallineultra-hard compact constructions of this invention include those havingthe following composition and liquidus temperature (LT) and solidustemperatures (ST), where the composition amounts are provided in theform of weight percentages:

-   81.25 Au, 18 Ni, 0.75 Ti, LT=960° C., ST=945° C.;-   82 Au, 16 Ni, 0.75 Mo, 1.25 V LT=960° C., ST=940° C.;-   20.5 Au, 66.5 Ni, 2.1 B, 5.5 Cr, 3.2 Si, 2.2 Fe, LT=971° C., ST=941°    C.;-   56.55 Ni, 30.5 Pd, 2.45 B, 10.5 Cr, LT=977° C., ST=941° C.;-   92.75Cu, 3 Si, 2 Al, 2.25 Ti, LT=1,024° C., ST=969° C.;-   82.3 Ni, 3.2 B, 7 Cr, 4.5 Si, 3 Fe, LT=1,024° C.; ST=969° C.; and-   96.4 Au, 3 Ni, 0.6 Ti, LT=1,030° C., ST=1,003° C.

Example “nonactive” braze materials useful for forming polycrystallineultra-hard compact constructions include those having the followingcomposition and liquid temperature (LT) and solid temperature (ST),where the composition amounts are provided in the form of weightpercentages:

-   52.5 Cu, 9.5 Ni, 38 Mn, LT=925° C., ST=880° C.;-   31 Au, 43.5 Cu, 9.75 Ni, 9.75 Pd, 16 Mn, LT=949° C., ST=927° C.;-   54 Ag, 21 Cu, 25 Pd, LT=950° C., ST=900° C.;-   67.5 Cu, 9 Ni, 23.5 Mn, LT=955° C., ST=925° C.;-   58.5 Cu, 10 Co, 31.5 Mn, LT=999° C., ST=896° C.;-   35 Au, 31.5 Cu, 14 Ni, 10 Pd, 9.5 Mn, LT=1,004° C., ST=971° C.;-   25 Su, 37 Cu, 10 Ni, 15 Pd, 13 Mn, LT=1,013° C., ST=970° C.; and-   35 Au, 62 Cu, 3 Ni, LT=1,030° C., ST=1,000° C.

As noted above, braze materials useful for forming polycrystallineultra-hard compact constructions can be active and react with thepolycrystalline ultra-hard material used to form the compact. In anexample embodiment, where such an active braze material is used, thebraze material can react with the polycrystalline ultra-hard material toform a reaction product therein and/or between it and the adjacentsupport member. The presence of such reaction product can operate toenhance the thermal and/or mechanical properties of the polycrystallineultra-hard material. For example, where the braze material includessilicon or titanium and the polycrystalline ultra-hard materialcomprises a polycrystalline diamond ultra-hard phase, the silicon ortitanium in the braze material reacts with the carbon in the diamond toform SiC or TiC.

In addition to the properties of being active or nonactive, brazematerials used to form polycrystalline ultra-hard compact constructionsof this invention can be selected based on their characteristic liquid(liquidus) or solid/crystallization (solidus) temperatures, as will bedescribed in greater detail below, for the purpose of facilitatingforming the constructions in a manner that intentionally reduces oreliminates the formation of voids and/or residual thermal stresses inthe resulting construction. Additionally, when constructions of thisinvention are to be attached to an end-use application device by weldingor brazing technique, it is also desired that the braze materialselected be one having a liquidus temperature that is higher than thewelding or brazing temperature used to attach the construction to theend-use device. For example, where the construction is provided in theform of a cutting element for attachment on a bit for drillingsubterranean formations, it is desired that the braze material have aliquidus/solidus temperature that is above that used to joinconventional cutting elements, e.g., having a PCD body and a WC-Cosubstrate, to such drill bits.

The support member used for forming polycrystalline ultra-hard compactconstructions of this invention can be formed from the same types ofmaterials disclosed above used for forming substrates for conventionalPCD compacts. In an example embodiment, the support member can be formedfrom a cermet material such as WC-Co.

A feature of the polycrystalline ultra-hard construction 10 illustratedin FIG. 1A is that the support member 14 extends both axially,circumferentially and radially around respective portions of the compact12, thereby providing a desired degree or reinforcement to the compactto improve the strength of the compact, and to improve the attachmentstrength between the compact and the support when the overallconstruction is attached to an end wear and/or cutting device and placedinto operation.

FIGS. 1B and 1C illustrate other example embodiment polycrystallineultra-hard compact constructions 40 of this invention comprising thesame general elements of a compact 42 having a polycrystalline diamondbody 44, e.g., formed from PCD or TSP, attached to a substrate 46. Asupport member 48 is attached to the compact 42 and includes an integralfirst section 50, that extends axially along an outside wall surface 52of the compact and that covers a desired circumferential portion of thecompact outside wall surface, and an integral second section 54 thatextends radially away from an end portion of the first section to coverat least a portion of the compact backside surface 56.

Additionally, the support member 48 of this example embodiment includesan integral third or front section 58 that extends radially from anopposite end of the axially extending support first section 50. Thesupport member third section 58 is designed to extend radially along andcover at least a portion of the compact front side surface 60, whichsurface is defined by the compact body 44.

The extent that the support member third section 58 extends radiallyalong the compact front side surface can and will vary depending on anumber of factors such as the type of materials used to form thecompact, the specific geometry of the compact, and/or the particularend-use application. In an example embodiment, the support member thirdsection 58 will extend radially to cover at least about 10 percent ofthe compact front side surface 60, preferably in the range of from about20 to 100 percent of the compact front side surface, and more preferablyin the range of from about 30 to 100 percent of the compact front sidesurface.

In a preferred embodiment, the support third section is sized so that itfunctionally provides a desired degree of support to the compact whileat the same time exposing a sufficient amount of the compact body frontside surface 60 to produce a sufficient working surface for theparticular wear and/or cutting application.

Configured in this manner, the support member 48 operates to not onlyprovide side or lateral support for the compact 42, via the supportmember first section 52, but the combined second or back section 54 andthird or front section 58 operate to provide axial support for thecompact. Thus, a feature of this invention embodiment is that the thirdsection operates to further enhance and stabilize the attachment betweenthe compact and the support member (both axially and radially), therebyhelping to improve the attachment strength and service life of thecompact portion of the construction 40. Further, when placed in certainend-use applications such as drilling or the like, the presence of thesupport member third section 58 can operate to shield the front sidesurface 60 of the compact 442 from some types of impacts, such as whenencountering downhole junk/debrazed cutters or the like.

Further, the support member 48 of this embodiment, comprising the backand front support sections, can be specially engineered to not onlyprovide an improved degree of axial support for the compact but canoperate to impose a compressive force on the compact, or place thecompact disposed axially between the back and front support sections ina state of compression. Placing the compact in a state of axiallydirected compression may be desired for compact constructions having apolycrystalline ultra-hard material/substrate attachment that couldbenefit from having an enhanced attachment strength. For example, whenthe polycrystalline ultra-hard material body is TSP and the substrateforming the compact is brazed or welded thereto, the placement of thiscompact in a state of compression by the support member can operate toextend the service life of the compact by reducing the chance of failuredue to delamination between the substrate and the body.

The support member of this embodiment can be constructed to place thecompact in a state of compression by forming the support member from amaterial having a thermal expansion property, e.g., a coefficient ofthermal expansion, that is greater than that of the compact, so that thesupport member expands and contracts in an amount that is relativelygreater than that of the compact. As described in greater detail below,during the process of attaching the compact to the support member, thetemperature of the assembly is increased to the temperature of the brazematerial selected to form the attachment therebetween.

During the heating stage, the support member expands in an amount thatis greater than the compact. Once the braze material is melted, theassembly is allowed to cool, thereby forming the desired attachment bondbetween the support member and the compact. During the cooling stage,the support member contract in an amount that is greater than thecompact, thereby through the presence of the support front and backsections operating to place the compact in a state of axial compression,which compression operates to improve the strength of the attachmentbetween the compact body and the substrate.

FIG. 1C illustrates a particular embodiment of the polycrystallineultra-hard compact construction 40 of this invention where the supportmember 48 is configured comprising front and back support sections 58and 54 that are sized to cover a substantial amount of the compact frontand backside surfaces 60 and 56, thereby operating to place the compact42 in a desired state, e.g., an optimal amount, of axial compressionsuitable for particular wear and/or cutting applications.

FIG. 1D is a front view of the construction embodiment of FIG. 1C thatillustrates the extent to which the support member first section extendscircumferentially around of the compact wall surface, and thatillustrates how the support member front section operates to cover thecompact front side surface. It is to be understood that the embodimentsillustrated in FIGS. 1C and 1D are provided for purposes of reference,and that embodiments of constructions comprising support members withfirst, second and third support sections configured differently thatthat illustrated therein are intended to be within the scope of thisinvention. For example, while FIGS. 1C and 1D show the support memberfront section covering the compact front side surface, it is to beunderstood that the front section can be configured to expose a portionof the compact front side surface sufficient to provide a desiredworking surface.

The support member 48 illustrated in the example embodiments of FIGS.1B, IC and ID include first, second, and third sections that areintegral with one another, i.e., that are formed from the same materialand that have a one-piece construction. Additionally, the materials thatare used to form the different elements of the construction 40 of thisexample embodiment can be the same as those described above for similarelements of the example embodiment construction illustrated in FIG. 1A.

FIG. 2A illustrates an example embodiment polycrystalline ultra-hardcompact construction 70 of this invention that is somewhat similar tothat described above and illustrated in FIG. 1A in that it includes acompact 72 that is attached to a support member 74, wherein the compactcomprises a polycrystalline ultra-hard material body 76 that is attachedto a substrate 78. However, unlike the integral or one-piececonstruction of the support member presented in FIG. 1A, the supportmember 74 of this construction embodiment comprises two portions thatare not integral with one another, i.e., the support member is of atwo-piece construction.

Specifically, the support member 74 includes a first portion 80 thatmakes up a majority of the support member and that includes a firstsection 82 that extends axially along an outside wall surface 84 of thecompact, and a second section 86 that extends radially along a backsidesurface 88 of the compact. The extent that the support member firstsection 82 circumferentially covers the compact, and the extent that thesupport member second section 86 radially covers the compact, can be thesame as that described above for the construction example illustrated inFIG. 1A.

In this particular construction embodiment, the first section 82 extendsaxially along only the compact substrate 78, and does not extend axiallyto cover an outside wall surface of the compact body 76. Rather, thesupport member 74 includes a second portion 90 that is configured to beattached to an axial end 92 of the support member first member 80 andthat extends axially therefrom to cover an outside wall surface of thecompact body 76. The second portion 90 can extend axially partially orwholly along the compact body 76 depending on the particular end-useapplication, and in a preferred embodiment extends along the entirelength of the compact body.

This example embodiment makes use of a two-piece support member 74 forthe purpose of more closely matching the wear resistance, thermalexpansion, and elastic moduli properties of the particular compactelements, e.g., the body or the substrate, that the respective supportmember portions will be attached to. For example, when the compact body76 is PCD and the compact substrate 78 is WC-Co, it may be desired touse a two-piece support member as illustrated in FIG. 2A, wherein thesecond portion 90 can be formed from a material having a relatively lowcobalt content, to more closely match the wear resistance, thermalexpansion, and elastic moduli properties of the PCD. In such example,the first portion 80 can be formed from a material having a relativelyhigher cobalt content, to both provide properties of strength andfracture toughness to the construction, and to also ensure a good weldor braze attachment with the end-use cutting and/or wear device. In anexample embodiment, the support member first and second portions 80 and90 can be formed from WC-Co, wherein the WC-Co material used to form thefirst member can have a cobalt content that is greater than that of thesecond member.

In another example embodiment, the support member 74 can comprise firstand second portions that are formed from the same types of material usedto form the compact substrate and body that will be attached thereto. Inan example where the compact comprises a PCD body attached to a WC-Cosubstrate, the support member first section can be formed from WC-Co andthe support member second section can be formed from PCD. Additionally,the support member portions can be joined together by HPHT process.Further, the support member 74 can be formed from a relativelylarger-sized compact that has been configured, e.g., by machiningprocess of the like, to accommodate placement of the polycrystallineultra-hard compact therein. For example, when the polycrystallineultra-hard compact comprises a PCD body bonded to a WC-Co substrate, thesupport member can be formed from a larger diameter compact alsocomprising a PCD body bonded to a WC-Co substrate, so that the supportmember first portion is formed from the WC-Co substrate, and the supportmember second portion is formed from the PCD body. Thus, when thepolycrystalline ultra-hard compact is fitted/nested within such asupport member, the compact PCD body is positioned adjacent the supportmember PCD second portion, and the compact WC-Co substrate is positionedadjacent the support member WC-Co first portion.

The materials used to form the remaining elements of the construction 70of this example embodiment can be the same as those described above forsimilar elements of the example embodiment construction illustrated inFIG. 1A.

FIG. 2B illustrates an example embodiment polycrystalline ultra-hardcompact construction 100 of this invention that is somewhat similar tothat described above and illustrated in FIG. 1B in that it includes acompact 102 that is attached to a support member 104, wherein thecompact comprises a polycrystalline ultra-hard material body 106 that isattached to a substrate 108. However, unlike the integral or one-piececonstruction of the support member presented in FIG. 1B, the supportmember 104 of this construction embodiment has a multi-piececonstruction. Specifically, the support member 104 includes a firstportion 110 that makes up a majority of the support member and thatincludes a first section 112 that extends axially along an outside wallsurface 114 of the compact 108, and a second section 116 that extendsradially along a backside surface 118 of the compact. The extent thatthe support member first section 112 circumferentially covers thecompact, and the extent that the support member second section 116radially covers the compact, can be the same as that described above forthe construction example illustrated in FIG. 1A.

In this particular construction embodiment, the first section 112extends axially along only the compact substrate 108, and does notextend axially to cover an outside wall surface of the compact body 106.Rather, the support member 104 includes a second portion 120 that isconfigured to be attached to an axial end 122 of the support memberfirst member 110 and that includes a section 124 that extends axiallytherefrom to cover an outside wall surface of the compact body 106.Unlike the support member second portion illustrated in FIG. 2A, thesecond portion 120 of this invention embodiment comprises a thirdsection 126 that extends radially from the second portion 120 to coverpart of all of the compact front side surface 128. The extent that thesupport second member third section 126 covers the compact front sidesurface can be the same as that described for the invention embodimentillustrated in FIG. 1B. The support member third or front section 126operates with the second section 116 to provide an improved degree ofaxial support to the compact 102 than that provided in the exampleembodiment illustrated in FIG. 2A, which may desired in certain end-useapplications.

As described above, the support member first and second portions 110 and120 illustrated in FIG. 2B can be formed from different materials likethose described above for the same reasons as already presented for theinvention embodiment illustrated in FIG. 2A, i.e., the first and secondmembers can be formed from materials having properties that are closelymatched to those of the section of the compact that they are positionedadjacent. For example, the materials selected to form the support firstand second portions may be chosen for the purpose of more closelymatching the wear resistance, thermal expansion, and/or elastic moduliproperties of the compact sections that each respective support memberwill be attached to. As described above for the example embodimentillustrated in FIG. 2A, the support member of FIG. 2B can also be formedfrom a relatively larger compact, comprising the same body and substrateas the polycrystalline ultra-hard compact, and that is configured bymachining process of the like to facilitate placement/nesting of thepolycrystalline ultra-hard compact therein.

Additionally, the support member of FIG. 2B can be formed from materialsthat operate to place the polycrystalline compact 102 disposed thereinin a desired state of axial compression. In an example embodiment, thesupport member 104 for such purpose would be formed from materialshaving a property of thermal expansion that is greater than that of thepolycrystalline ultra-hard compact for the reasons described above forthe embodiment of FIGS. 1B, 1C and 1D.

Further, the support member embodiment illustrated in FIG. 2B canadditionally be configured such that the support member second and thirdsections extend along approximately 100 percent of the compactrespective back and front side surfaces, as illustrated in FIGS. 1C and1D.

The materials used to form the remaining elements of the construction100 of this example embodiment can be the same as those described abovefor similar elements of the example embodiment construction illustratedin FIG. 1A.

The support member first and second portions of the invention embodimentillustrated in FIGS. 2A and 2B are attached to adjacent surfaces of therespective compact body and compact substrate by use of a braze material94 and 130 respectively. The braze material used to attach the supportmember first portion to its respective part of the compact can be thesame or different from that used to attach the support member secondportion to its respective part of the compact. Additionally, the brazematerial that is used to attach the support member first and secondportions together can be the same as or different from that used toattach the first and second portions to the compact. The support memberfirst and second portions can be attached to one another, e.g., bybrazing process, prior to or after one or both have been attached torespective parts of the compact. Alternatively, in the event that thesupport member itself is formed from a polycrystalline ultra-hardcompact, that has been specially configured to accommodate the compacttherein, the support member first and second portions will have beenattached to one another by the HPHT process used to sinter and form thecompact.

Although the polycrystalline ultra-hard compact construction embodimentsillustrated in FIGS. 1A, 1B, 1C, 2A and 2B display an interface betweenthe compact and the support member as being planar, i.e., having acontinuous and uninterrupted surface configuration, it is to beunderstood that the interface between the compact and the support memberand/or between the different portions or sections of a support member,i.e., in the case where the support member is of a multi-piececonstruction, can be of a nonplanar configuration depending on suchfactors as the types of materials used to form the compact and thesupport members, the types of braze materials used to attach the supportmembers and the compacts, as well as the particular end-use applicationfor the construction of this invention.

For example, the invention embodiment of FIG. 1A illustrates acompact-support member interface characterized by continuous axiallydirected (having a constant diameter) and/or radially directed (having aplanar surface) interfacing surfaces. However, if desired, the interfacebetween the respective compact sections and the first and/or secondsection of the support member can be nonplanar, and can be characterizedby noncontinuous, irregular, and/or interrupted surface features or thelike, depending on the factors noted above. In situations where agreater degree of mechanical strength is desired between the attachedcompact and the support member, it may be desired that the interfacetherebetween be configured having nonplanar surface features to providean increased attachment surface area.

As described above, the type of braze material that is used to form thepolycrystalline ultra-hard compact constructions of this invention canbe the same throughout the construction or can be different for the samereasons described above. Additionally, the different members ofmulti-part support members used to make the construction (as illustratedin FIGS. 2A and 2B) can be formed from the same or different types ofmaterials as described above for the other multi-part support memberconstruction example embodiments. Additionally, the interface surfacesbetween the different sections of the compact and support member can beplanar or nonplanar, depending on the particular end use application.

FIGS. 3A and 3B illustrate an example embodiment polycrystallineultra-hard compact construction 130 of this invention as attached to anend-use device 132. The construction 130 comprises a compact 134, havinga polycrystalline ultra-hard body 136 attached to a substrate 138,wherein the compact is attached to a support member 140. In an exampleembodiment, the compact is configured in the form of a cutting element,e.g., a shear cutter, for use with a drill bit, and comprises a PCD bodyattached to a WC-Co substrate.

The support member 140 includes a first section 142, that extendsaxially along a length of the compact and that extends circumferentiallyaround a major portion of the compact as best illustrated in FIG. 3B.Configured in this manner, the support member first section operates toprovide an enhanced degree of attachment strength to the compact. Unlikethe support members illustrated in FIGS. 1A, 1B, 1C, 2A and 2B, thesupport member 140 of this particular embodiment does not include asecond section extending radially along a backside surface of thecompact. Accordingly, it is to be understood that support members asused with compacts to form constructions of this invention may or maynot include such second section, and the presence of such will dependon, inter alia, the end-use application.

The support member 140 of this embodiment includes a front supportsection 144 that extends radially inwardly from an end of the firstsupport section 142 positioned adjacent a front side surface 146 of thecompact PCD body 136. The front section 144 is sized to cover a desiredportion of the PCD body front side surface as described above. The firstand front support sections are integral with one another and the supportmember of this example embodiment is of a one-piece construction.However, it is to be understood that the support member can just aseasily be a multi-piece construction as discussed above.

The support member 140 illustrated in this invention embodiment has anonplanar outside surface 148 for the purpose of providing an enhancedmechanical attachment with the adjacent surface of the end-use device,e.g., by welding or brazing technique. In an example embodiment, thesupport outside surface 148 is configured having one or more surfacefeatures 150 that are designed to provide an enhanced mechanical fitbetween the support and the end-use device to increase the mechanicalstrength of the attachment therebetween. In this example, the surfacefeatures are provided in the form of projections configured to cooperatewith complementary features in the adjacent surface of the end-usedevice. However, it is to be understood that the exact configuration ofthe nonplanar interface and/or number of support surface featuresprovided to produce the same can and will vary within the scope of thisinvention.

FIG. 3B illustrates the extent to which the support member 140 can beconfigured to provide radial or lateral support to the compact 134 whenattached to an end-use device. In this particular example, the supportmember first section 142 is configured to extend circumferentiallyaround a substantial portion of the element outside surface, e.g., alongmore than 50 percent of the compact circumferential surface. In anexample embodiment, the support member first section can be constructedto extend circumferentially around about 50 to 100 percent of thecompact wall surface, the extent depending on the end-use application.

Accordingly, it is to be understood that for support memberconfigurations having one of a second or third section, the supportmember may be configured with a first section that provides greater thana 50 percent circumferential wrap and is not limited by the technique ofplacing the compact therein, i.e., with only one of a support second orthird section, the compact can be inserted axially within the supportmember. With support members configured having both a second and thirdsection, the first section wrap is limited to 50 percent because of thelimitation involved in placing/loading the compact radially within thesupport member.

In the example embodiment of FIG. 3A and 3B, the support member firstsection 142 is configured having a decreasing radial thickness as itapproaches a section of the compact that is generally aligned with anedge portion of the end use device. This can be achieved, for example,by forming a hole through the support member having an axis that isoffset from the that of the support member.

FIGS. 4A and 4B illustrate an example embodiment polycrystallineultra-hard compact construction 152 of this invention as attached to anend-use device 154. The construction 152 is similar to that illustratedin FIGS. 3A and 3B except that the support member 156, that is attachedto the compact 158, lacks a front section covering a portion of thecompact front side surface. The construction 152 is somewhat similar tothat described above and illustrated in FIG. 3A in that the supportmember 156 also does not include second section that extends radiallyinwardly along the compact backside surface. Like the constructionembodiment illustrated in FIGS. 3A and 3B, the support member 156 ofthis construction embodiment 152 also has a nonplanar outside surface160 for the purpose of providing an enhanced mechanical attachment withthe adjacent end-use device, e.g., by welding or brazing technique.Further, like the embodiment of FIGS. 3A and 3B, the support member 156comprises a first section that wraps circumferentially around a majorityof the compact wall surface.

Polycrystalline ultra-hard compact constructions of this invention caninclude a compact having a polycrystalline ultra-hard material bodyconfigured in the form of a tablet having a cylindrical outside wallsurface with a defined radius, and having a defined thickness. It is tobe understood that the radial and axial dimensions of thepolycrystalline ultra-hard material body can and will vary depending onthe particular tooling, cutting and/or wear application. In an exampleembodiment, for purposes of reference, the polycrystalline ultra-hardbody can have a diameter in the range of from about 9 mm to 22 mm,although there are niche applications for body diameters of from about 6mm and 26 mm as well. Example embodiment constructions of this inventioncan comprise polycrystalline ultra-hard bodies within the above-noteddiameter ranges and having an axial thickness of from about 0.5 mm to4.0 mm. Again, it is to be understood that these ranges are providedonly for purposes of reference and example and are not intended to belimiting of polycrystalline ultra-hard compact constructions of thisinvention.

The compact substrate that is attached to the polycrystalline ultra-hardmaterial body preferably has a diameter that is the same or very closeto that of the body, and that has an axial length that operates to bothprovide a desired degree of support to the body and provide a desireddegree of attachment surface to the support member. It is to beunderstood that the exact radial and axial dimensions of the substratecan and will vary depending on the particular cutting and/or wearapplication.

The type of braze materials that are used to attach the compact to thesupport member and/or different members or sections of the supportmember together can and will vary depending on such factors as the typesof materials used to form the compact and/or the types of material usedfor to form the support member and/or support member sections orelements.

A feature of the polycrystalline ultra-hard compact constructions ofthis invention is that the support member first section extendscircumferentially around a portion of the compact outside wall surface.The interface geometry provided along the interface between the supportmember and compact is well suited for certain cutting and/or wearapplications calling for a high degree of bond strength with thecompact. The adjacent surfaces of the compact and the support memberfirst section are therefore configured in a manner that provides a highdegree of surface area along the interface to further enhance the bondstrength therebetween. Additionally, this interface configuration mayprovide some compressive radial residual stresses that could operate toenhance cutter performance.

Polycrystalline ultra-hard compact constructions of this inventioncomprise a support member formed from one or more support sections thatare specially configured to attach with the compact to help improve thebond strength of the compact body within the construction and to theend-use wear and/or cutting device. The support members may includesections that are configured to extend radially along one or more of thecompact front and back side surfaces to provide an improved degree ofaxial support and/or to place the compact in a state of compression tofurther improve the attachment strength with the compact and between thecompact body and substrate.

Where the support member is provided as a multi-piece construction, thesupport sections are configured to both fit together with one anotherand with the compact in manner that enables movement of the supportmember sections relative to one another and relative to the compactduring the attachment process to avoid the formation of any unwantedgaps or voids, thereby operating to minimize or eliminate the unwantedpresence of residual thermal stresses that could otherwise exist withinthe construction, and to minimize or eliminate the presence of anyunwanted stress concentrations within the construction that can occurduring end-use operation.

For example, in the polycrystalline ultra-hard compact constructionembodiments described above and illustrated FIGS. 2A and 2B, the compactis attached to a support member comprising at least two separate supportsections. The use of a support member comprising two or more supportsections that are movable relative to one another and relative to thecompact during the attachment process operates to minimize or eliminatethe formation of unwanted residual thermal stresses in the constructionthat can be created during the attachment process. When the attachmentbetween the support member sections and/or the compact is provided by abraze material during a brazing process, the braze material is known toundergo a certain degree expansion. Using a support member having two ormore support sections in forming constructions of this invention enablesa desired degree of movement to take place amongst the compact andsupport member sections during the brazing process to thereby avoid orminimize formation of unwanted thermal stresses within the resultingassembled construction.

As mentioned briefly above, if desired, the support member first sectioncan comprise two or more support portions, i.e., side support sections.The use of such two-piece side support member operates to furtherimprove the attachment strength between the compact within theconstruction. Additionally, when the support member further includes aseparate front or back support section, the use such further separatesupport sections operates to further improve the degree to which thesupport member sections can move relative to one another and relative tothe compact body during the brazing process, thereby further enhancingthe ability to minimize or eliminate the occurrence of unwanted residualthermal stress within the resulting construction. Additionally, the useof a multi-piece support member permits the use of a variety ofdifferent mechanical interlocking features between the different supportmember portions and/or the compact, further enhancing the degree ofattachment strength that can be gained by this invention.

Polycrystalline ultra-hard compact constructions of this invention canbe formed using a single-type of braze material to braze together thesupport member and the compact, and/or to braze together the differentsupport member portion. In an example embodiment, an active brazematerial can be used to braze both the compact PCD body to the supportmember first or side section, as well as braze together the supportmember sections that are adjacent the PCD body. It is to be understoodthat the specific type of braze material used as the single type ofbraze material to attach the construction can and will vary depending onsuch factors as the type of material used to form the polycrystallineultra-hard compact, the type of material used to form the supportmember, and the ultimate end-use application.

Alternatively, polycrystalline ultra-hard compact constructions of thisinvention can be formed using two or more different types of brazematerials to further suppress unwanted void formation and increase thestrength of the resulting construction. For example, a first type ofbraze material can be used to join the compact PCD body to one supportmember section, while another type of braze material can be used to jointhe compact substrate to another support member section, and/or to joindifferent portions of the support member together. In such an example,it may be desirable to use an active braze material to join the compactPCD body to the respective support member section, and use a nonactivebraze material to join the compact substrate to the respective supportmember section and/or to join support member portions together. In thisexample, the active braze material will react with and form a strongbond with the compact PCD body, which is desired for the purpose ofimproving the bond strength of the compact PCD body within theconstruction.

The different braze materials used in these constructions can beselected on the basis of the being active or nonactive and/or on thebasis of the melting (liquidus) temperatures and/or solidifying(solidus) or crystallizing temperatures of the braze materials. Forexample, it may be desirable to use a braze material, having arelatively high melting temperature (high crystallization temperature),for joining the compact and/or different parts of the compact to asupport member, and use relatively lower melting temperature (lowercrystallization temperature) braze material for joining the supportmembers together. During the brazing process the braze material isheated to its melting temperature while the components to be brazedtogether are held in an assembled state. Once melted, the braze materialfills the spaces between the components, after that the braze materialis allowed to cool. During the cooling process, the braze materialundergoes crystallization, that causes a contraction of the brazematerial.

In this example, selecting a higher melting temperature braze materialto attach the compact to a support member will cause such braze materialto crystallize first during cooling while the relatively lower meltingtemperature braze material is still in a liquid phase. This selectivechoice of using different melting temperature braze materials enablesthe compact to be attached to the support member without resistance fromthe other support members, which resistance to movement can cause anunwanted formation of residual thermal stress within the construction.As the assembly continues to cool, the lower melting point brazematerial undergoes crystallization and forms a desired attachmentbetween the support members.

Thus, a feature of polycrystalline ultra-hard compact constructions ofthis invention is that they permits the selective use of different typesof braze materials to both provide an improved bond strength with thecompact and/or the different parts of the compact and further avoids theunwanted creation of residual thermal stresses within the resultingconstruction.

Thus, it is to be understood that the polycrystalline ultra-hard compactconstructions described herein and illustrated in the figures can beformed using a single-type of braze material, or can be form using twoor more different types braze materials. It is to be understoodpolycrystalline ultra-hard compact constructions can be formed using avariety of different types of braze materials to form attachmentsbetween a number of different adjacent compact body and support membersurfaces, and that all such available variations formed by using suchdifferent types of braze materials are within the scope of thisinvention.

The materials useful for forming the support member or portions thereofaccording to principles of this invention include those capable ofproviding a desired level of structural strength and rigidity to theconstruction to thereby enable attachment and use of the constructionwith a desired cutting and/or wear device. It is also desired that thesupport member used to form constructions of this invention be made frommaterials having properties that facilitate attachment to one anotherand to the compact by brazing process or the like. Further, it isdesired that the materials used to form the support member enable theconstruction to be attached to the end use cutting and/or wear device byconventional method, e.g., by brazing or welding or the like.

Suitable materials useful for making support members include, and arenot limited to, carbides, nitrides, carbonitrides, ceramic materials,metallic materials, ultra-hard materials such as those including diamondand/or cubic boron nitride components, cermet materials, and mixtures,combinations, and alloys thereof. Materials useful for forming thesupport members can be selected from the same general types of materialsused to form substrates for conventional PCD materials, or used to formsubstrates for conventional thermally stable polycrystalline diamondcompact constructions, including cermet materials such as cementedtungsten carbide.

In addition to having the ability to use different types of brazingmaterials when forming constructions of this invention, suchconstructions can also be formed by using a support member having twosupport portions that are made from the same or different types ofmaterials. For example, constructions of this invention can be formedhaving a support member or portions forming the same that are all formedfrom the same material. In the example where the support member is of aunitary construction, it will be formed from the same material. In theexample where the support member is formed from two separate portions,such portions can be formed from different materials to provide afurther variant that can be adjusted for providing constructions havingimproved bond strength and reduced residual thermal stress.

When using the term “different” in reference to materials used to formboth the braze material and materials used to form support memberportions, it is to be understood that this includes materials thatgenerally include the same constituents, but may include differentproportions of the constituents and/or that may include differentlysized constituents, wherein one or both such features operate to providea different mechanical and/or thermal property in the material.

Polycrystalline ultra-hard compact constructions of this invention arespecially engineered to include a support member, that can be of anintegral or multi-piece construction and that can be made from the sameor different material, and that can be attached to one another and tothe compact using the same or a different braze material. Constructionsconfigured in this manner enable a designer to vary one or more of thesefeatures for the purpose of achieving a desired improvement in bondstrength, and/or a desired reduction in residual thermal stress, and/ora desired reduction in stress concentrations within the construction tomeet the needs of different end-use applications. Further,polycrystalline ultra-hard compact constructions of this invention canbe attached by conventional methods, such as by brazing, welding or thelike, to a variety of different end-use application devices.

Polycrystalline ultra-hard compact constructions of this invention canbe used in a number of different applications, such as tools for mining,cutting, machining, milling and construction applications, whereinproperties of thermal stability, and/or wear and abrasion resistance,mechanical strength, reduced thermal residual stress, and reduced stressconcentrations are highly desired. Polycrystalline ultra-hard compactconstructions of this invention are particularly well suited for formingworking, wear and/or cutting elements in machine tools and drill andmining bits such as roller cone rock bits, percussion or hammer bits,diamond bits, and shear cutters used in subterranean drillingapplications.

FIG. 5 illustrates a drag bit 162 comprising a plurality of cuttingelements made from polycrystalline ultra-hard compact constructions ofthis invention configured in the form of shear cutters 164. The shearcutters 164 are each attached to blades 166 that extend from a head 168of the drag bit for cutting against the subterranean formation beingdrilled. The shear cutters 164 are attached by welding or brazingtechnique to the blades and are positioned to provide a cutting surface.

FIG. 6 illustrates a rotary or roller cone drill bit in the form of arock bit 170 comprising a number of polycrystalline ultra-hard compactconstructions of this invention provided in the form of wear or cuttinginserts 172. The rock bit 170 comprises a body 174 having three legs176, and a roller cutter cone 178 mounted on a lower end of each leg.The inserts 172 can be formed according to the methods described above.The inserts 172 are provided in the surfaces of each cutter cone 178 forbearing on a rock formation being drilled.

FIG. 7 illustrates the inserts described above as used with a percussionor hammer bit 180. The hammer bit comprises a hollow steel body 182having a threaded pin 184 on an end of the body for assembling the bitonto a drill string (not shown) for drilling oil wells and the like. Aplurality of the inserts 172 is provided in the surface of a head 186 ofthe body 182 for bearing on the subterranean formation being drilled.

Other modifications and variations of polycrystalline ultra-hard compactconstructions comprising a polycrystalline ultra-hard compact attachedto a support member configured in the manner described above withreference to the figures will be apparent to those skilled in the art.It is, therefore, to be understood that within the scope of the appendedclaims, this invention may be practiced otherwise than as specificallydescribed.

What is claimed is:
 1. A method of preparing a polycrystallineultra-hard compact construction, comprising: forming a polycrystallinediamond compact by subjecting a volume of precursor diamond grains tohigh pressure/high temperature conditions in the presence of acatalyzing material and a substrate material to provide apolycrystalline diamond body joined with the substrate, wherein thediamond body comprises a material microstructure of bonded togetherdiamond particles; attaching a support member to at least a partialaxial length of an outside wall surface of the compact by the use of abraze material, wherein the support member includes a first section thatextends axially along at least a portion of the polycrystalline diamondbody of the compact and that at least partially covers a circumferentialsurface of the compact, and wherein the support member has an outersurface to facilitate attachment to an end-use device.
 2. The method asrecited in claim 1 wherein the support member includes a second sectionthat extends radially away from the first section and that is attachedto one of a backside or front side surface of the compact by use of abraze material.
 3. The method as recited in claim 2 wherein the secondsection covers from about 30 to 100 percent of the front or backsidesurface of the compact.
 4. The method as recited in claim 2 wherein thesupport member second section is separate from the first section andattached thereto by the use of a braze material.
 5. The method asrecited in claim 4 wherein different braze materials are used to attachthe support member to the compact than to attach the support membersections together.
 6. The method as recited in claim 2 wherein thesupport member first and second sections are integral with one anotherso the support member is of a one-piece/unitary construction.
 7. Themethod as recited in claim 1 wherein the support member includes asecond section and a third section that each extend radially away fromopposed ends of the first section and that are attached to respectivefront side and backside surfaces of the compact by use of a brazematerial.
 8. The method as recited in claim 7 wherein the second sectioncovers from about 30 to 100 percent of the front or backside surface ofthe compact.
 9. The method as recited in claim 8 wherein the thirdsection covers from about 30 to 100 percent of the other of the front orbackside surface of the compact.
 10. The method as recited in claim 7wherein the support member first section is integral with at least oneof the second or third sections to form a one-piece/ unitaryconstruction.
 11. The method as recited in claim 7 wherein the supportmember first, second or third sections are not integral with theremaining sections.
 12. The method as recited in claim 1 whereinattaching comprises using more than one type of braze materialinterposed between the compact and the support member.
 13. The method asrecited in claim 1 wherein the substrate comprises a cermet material.14. The method as recited in claim 1 wherein at least a portion of thepolycrystalline diamond body is substantially free of a catalystmaterial.
 15. The method as recited in claim 1, further comprisingattaching at least a portion of the outer surface of the support memberto the end-use device, wherein the end-use device is a bit.
 16. Themethod of claim 1, wherein the support member extends circumferentiallyaround from at least a major portion to at most 100 percent of theoutside wall surface of the compact.
 17. The method as recited in claim1 wherein the construction comprises a longitudinal axis, wherein thediamond body comprises a circumferential surface defined about saidlongitudinal axis, wherein at least a portion of said circumferentialsurface is circular about said longitudinal axis, wherein the firstsupport member comprises a circumferential surface defined about saidlongitudinal axis, and wherein at least a portion of said first supportmember circumferential surface is circular about said longitudinal axis.18. A bit for drilling subterranean earthen formations comprising a bodyand a number of blades projecting outwardly from the body, the bitfurther comprising a number of cutting elements that are attached to theblades, wherein at least one of the cutting elements include apolycrystalline diamond compact construction prepared by the process of:forming a polycrystalline diamond compact by subjecting a volume ofprecursor diamond grains to high pressure/high temperature conditions inthe presence of a catalyzing material and a substrate material toprovide a polycrystalline diamond body joined with the substrate,wherein the diamond body comprises a material microstructure of bondedtogether diamond particles; attaching a support member to at least apartial axial length of an outside wall surface of the compact by theuse of a braze material, wherein the support member includes a firstsection that extends axially along at least a portion of thepolycrystalline diamond body of the compact and at least partiallycovers a circumferential surface of the compact, and wherein the supportmember has an outer surface to facilitate attachment to the bit blade.19. The bit as recited in claim 18 wherein the support member-extendscircumferentially around from at least a major portion to at most 100percent of the outside wall surface of the compact.
 20. The bit asrecited in claim 18 wherein the support member includes sectionsextending radially along 30 to 100 percent of the compact front side andback side surfaces.
 21. The bit as recited in claim 18 wherein attachingthe support member comprises using different braze materials between thecompact and support member.
 22. The bit as recited in claim 18 whereinthe support member is a one-piece/unitary construction.
 23. Theconstruction as recited in claim 18 wherein forming the polycrystallinediamond compact further comprises forming at least a portion of thepolycrystalline diamond body that is substantially free of a catalystmaterial.
 24. A method of manufacturing a polycrystalline ultra-hardcompact construction comprising: forming a polycrystalline diamondcompact by subjecting a volume of precursor diamond grains to highpressure high temperature conditions in the presence of a catalyzingmaterial and a substrate material to provide a polycrystalline diamondbody joined with the substrate, wherein the diamond body comprises amaterial microstructure of bonded together diamond particles; attachinga support member to at least a partial axial length of an outside wallsurface of the compact by the use of a braze material, wherein thesupport member includes a first section that extends axially along atleast a portion of the polycrystalline diamond body of the compact andat least partially covers a circumferential surface of the compact, andthe support member further includes a second section that extendsradially away from the first section and that is attached to one of abackside or front side surface of the compact by use of a brazematerial, and the support member has an outer surface to facilitateattachment with an end-use device.
 25. The method as recited in claim 24wherein the support member further includes a third section so that eachof the second and third sections extend radially away from opposed endsof the first section and are attached to respective front side andbackside surfaces of the compact by use of a braze material.
 26. Themethod as recited in claim 25 wherein the support member second andthird sections extend radially along 30 to 100 percent of the compactfront side and back side surfaces.
 27. The method as recited in claim 26further comprising placing the compact in a state of axial compressionwithin the support member when the support member is attached to thecompact.
 28. A method of preparing a polycrystalline ultra-hard compactconstruction, comprising: obtaining a polycrystalline ultra-hard compacthaving a polycrystalline ultra-hard body that is joined to a substrateby a high pressure high temperature condition, wherein the bodycomprises a material microstructure of bonded together ultra-hardparticles; and attaching a support member to a surface of the compactwith a braze material, wherein the support member includes a firstsection extending axially along at least a portion of the substrate andextending circumferentially around at least a major portion of thecompact.
 29. The method of claim 28, wherein the first section of thesupport member extends circumferentially around at most 100 percent ofthe surface of the compact.
 30. The method of claim 28, wherein thefirst section of the support member extends circumferentially aroundsubstantially 100 percent of the surface of the compact.
 31. The methodof claim 30, wherein the support member has a longitudinal axis and thecompact has a longitudinal axis that is offset from the support memberlongitudinal axis.
 32. The method of claim 28, wherein the first sectionof the support member includes a first region adjacent the bodycomprising a first material and a second region adjacent the substratecomprising a second material, and wherein the first material comprises apolycrystalline ultra-hard material.
 33. The method of claim 32, whereinthe first region is attached to the body by a first braze material andthe second region is attached to the substrate by a second brazematerial.
 34. The method of claim 33, wherein the first braze materialis an active braze material and the second braze material is a nonactivebraze material.
 35. The method of claim 33, wherein the support memberincludes a second section that extends radially away from the firstsection and is attached to front side surface of the compact and thirdsection that extends radially away from the first section and isattached to a backside surface of the compact, and wherein the secondsection and the third section cover from about 30 to 100 percent of thefront and backside surface of the compact.
 36. The method of claim 35,wherein the second section is attached to the compact by a third brazematerial and the third section is attached to the compact by a fourthbraze material, and wherein the third braze material differs from thefourth braze material.
 37. The method of claim 28, wherein at least aportion of the first section of the support member varies in radialthickness.
 38. The method of claim 28, wherein the support memberextends axially along at least a portion of the substrate.
 39. Themethod of claim 28, wherein the support member extends axially along atleast a portion of the body and at least a portion of the substrate. 40.The method of claim 28, wherein the polycrystalline ultra-hard materialcomprises polycrystalline diamond.
 41. A method of preparing apolycrystalline ultra-hard compact construction comprising: obtaining apolycrystalline ultra-hard compact having a polycrystalline ultra-hardbody that is joined to a substrate, wherein the body comprises amaterial microstructure of bonded together ultra-hard particles; andattaching a support member to a surface of the compact, wherein thesupport member includes a first section extending axially along at leasta portion of the body and the substrate of the compact, the firstsection of the support member includes a first region adjacent the bodycomprising a first material and a second region adjacent the substratecomprising a second material, and the first material has one or moreproperties more closely matching the properties of the body than thesecond material.
 42. The method of claim 41, wherein at least a portionof the support member is attached to the body by a braze material. 43.The method of claim 41, wherein at least a portion of the first regionof the support member is attached to the body by a braze materialcomprising a metal alloy comprising two or more materials selected fromthe group consisting of Ag, Au, Cu, Ni, Pd, B, Cr, Si, Ti, Mo, V, Fe,Al, Mn, and Co.
 44. The method of claim 41, wherein the first materialcomprises a polycrystalline diamond material.
 45. The method of claim41, wherein the support member includes a second section that extendsradially away from the first section and is attached to either a frontside surface of the compact or a backside surface of the compact, andwherein the second section covers from about 30 to 100 percent of thefront or backside surface of the compact.
 46. A method of preparing apolycrystalline ultra-hard compact construction, comprising: obtaining apolycrystalline ultra-hard compact having a polycrystalline ultra-hardbody that is joined to a substrate by a high pressure high temperaturecondition, wherein the body comprises a material microstructure ofbonded together ultra-hard particles; and attaching a support member toa surface of the compact, wherein the support member includes a firstsection extending axially along at least a portion of the compact andextending circumferentially around at least a major portion of thecompact, wherein the first section of the support member includes afirst region extending circumferentially around at least a portion ofthe body comprising a first material and a second region extendingcircumferentially around at least a portion of the substrate comprisinga second material, and wherein the first material comprises apolycrystalline ultra-hard material.
 47. The method of claim 46, whereinthe first section of the support member extends circumferentially aroundat most 100 percent of the surface of the compact.
 48. The method ofclaim 46, wherein the first section of the support member extendscircumferentially around substantially 100 percent of the surface of thecompact.
 49. The method of claim 46, wherein the first region isattached to the body by a first braze material and the second region isattached to the substrate by a second braze material.